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The shelf panel, situated on the beams of the racking system, acts as a robust platform for storing goods securely. Our manufacturing expertise focuses on producing double-bend shelf panels, which offer superior durability compared to the single-bend type. Moreover, this design eliminates sharp exposed edges, prioritizing user safety.
Real case-Main Techinical Parameters
Flow chart
Hydraulic decoiler with leveler--Servo feeder--Hydraulic punch--Roll forming machine--Hydraulic cut and stamping--Out table
Main Technical Parameters:
1. Line speed: Adjustable from 0 to 4 m/min
2. Profiles: Various sizes with consistent height, differing in width and length
3. Material thickness: 0.6-0.8mm (for this application)
4. Suitable material: Galvanized steel
5. Roll forming machine: Utilizes a cantilevered double-wall panel structure and chain driving system
6. Number of forming stations: 13
7. Cutting system: Simultaneous cutting and bending; roll former remains operational during the process
8. Size adjustment: Automatic
9. PLC cabinet: Equipped with Siemens system
Real case-Description
Hydraulic Decoiler with Leveler
The core expansion can be adjusted to fit steel coil inner diameters ranging from 460mm to 520mm. During uncoiling, outward coil retainers ensure the steel coil stays securely on the decoiler, enhancing worker safety by preventing the coil from slipping off.
The leveler is equipped with a series of rollers that progressively flatten the steel coil, effectively removing residual stresses.
Servo Feeder & Hydraulic Punch
(1) Independent Hydraulic Punching
This punching system operates independently, not sharing the same machine base with the roll forming machine, ensuring seamless and uninterrupted performance of the roll forming process. The feeder is powered by a servo motor, which has minimal start-stop time delay. This allows for precise control over the steel coil's advancement in the coil feeder, ensuring accurate and efficient punching.
(2)Optimized mold solution
The punched holes on the shelf panel are categorized into notches, functional holes, and bottom continuous holes. Due to the varying frequencies of these hole types on a single shelf panel, the hydraulic punch machine is equipped with four dedicated molds, each designed for one specific type of hole. This setup is tailored to efficiently complete each type of punching, thereby enhancing overall efficiency and productivity.
Encoder & PLC
The encoder translates the sensed steel coil lengths into electrical signals, which are then sent to the PLC control cabinet. Inside the control cabinet, operators can manage production speed, single production output, cutting length, and other parameters. With accurate measurements and feedback from the encoder, the cutting machine can maintain cutting errors within ±1mm.
Roll forming machine
Before entering the roll forming machine, the steel coil passes through adjustable guiding bars. These bars are adjusted according to the width of the steel coil, ensuring it aligns precisely with the production line machinery along the center line. This alignment is essential for maintaining the straightness and load-bearing capacity of the shelf panel.
This forming machine utilizes a double-wall cantilever structure. Since forming is required only on two sides of the panel, a cantilever roller design is used to conserve roller material. The chain driving system propels the rollers and applies force to the steel coil, enabling its advancement and forming.
The machine can produce shelf panels of various widths. Workers input the desired dimensions into the PLC control cabinet panel. Once the signal is received, the forming station on the right side automatically moves along the rails. The forming points on the steel coil adjust with the movement of the forming station and forming rollers.
An encoder is also installed to detect the distance of the forming station's movement, ensuring accuracy when changing sizes. Additionally, two position sensors are included: one for detecting the farthest distance and another for the nearest distance the forming station can move on the rails. The farthest position sensor prevents excessive movement of the forming station, avoiding slippage, while the nearest position sensor prevents the forming station from moving too far inward, thus avoiding collisions.
Hydraulic cutting and bending
The shelf panels produced on this production line feature double bends on the wide side. We've designed an integrated cutting and bending mold, enabling both cutting and double bending within a single machine. This design not only conserves production line length and factory floor space but also reduces production time.
During cutting and bending, the cutting machine base can move backward and forward in synchronization with the roll forming machine's production speed. This ensures uninterrupted production and enhances efficiency.
Other solution
If you're intrigued by single-bend shelf panels, simply click on the image to delve deeper into the detailed production process and watch the accompanying video.
Key differences:
The double-bend type offers superior durability, while the single-bend type also adequately meets storage needs.
The edges of the double-bend type are not sharp, enhancing safety, whereas the single-bend type may have sharper edges.
1. Decoiler
2. Feeding
3.Punching
4. Roll forming stands
5. Driving system
6. Cutting system
Others
Out table
